Process of forming objects with integral cup and shank



' 1,642,696 C. J RA TEIKE P ROCE'SS OF FORMING OBJECTS WITH INTEGRAL CUP AND SHANK Filed May 9, 1924 2 Sheets-Shoat 1 1 v WHHIHHH IIIIIIIIIIIJ. H i l v Patented Sept. 20, i v I 1,642,696 UNITED STATES PATENT OFFICE.

CHARLES J'- RL'IEIKI, OI CHICAGO, ILLINOIS, AS81611)! '10 GHIGA GO'I'GBGIHG & II'G.

' 00., CKIOAGO, ILLINOIS, A CORPORATION OF ILLINOIS.

raocnss or some omc'rs wrrn m'rmm cur um smx.

' Application mm lay a, 1m) mm Io. 112,057.

This invention relates to a method prothe rtion remote therefrom, and thereby ducing electric cable attachingl terminals or deve oping longitudinal flowing of the metal other objects embodying in t eir construc- 0f the shank awayfrom the cup, with the tion a cup or socket portion and a shank result of elongating the ultimate shank and portion inegral therewith; and the invendeveloping substantial laterally extendin 00 tion has for its object to produce such an shoulders at the 1uncture of the shank wit object from a solid slug, without waste incithe cup; this portlon of the process being dent to drilling, trimming, or finishing; to preferably accomplished in a plurality of accomplish the result with a minimum exsteps, of whlch'the ultimate step reduces the penditure of power; and to provide a series flattened shank' to umform thickness 65 of steps afiording superior control over the throughout. I I disposrtion of the metal in passing 1t from In order thatthe, Invention may; be fully its original to its ultimate form. understood, theseveral stages of t e process One underlying feature of the mventlon are illustrated in the *accompanymg draw-.

consists in converting a solid slu oi metal mg, both by the ob ec t as it exists at the 70 into an object having an integra cup and several stages, andby mstrumentalities em shank, by subject g the slug to the action ployed for developing each stage. In said of a punch havin a transversedimension dravjung- I y substantially less than that of the cup to be F gures 1, 2, 3, 4', 5, 6 represent in 20. formed, while the slug is confined 1n the side elevation or longitudmal sect1on, six 15 cavity of a die which defines the exterior stages in the develop1nent of the object,

' dimension of the cup as wellas that of the commencm -W1th the slug or rough piece of shank to be formed, forcing the punch into s0l1 d meta and ending with t e finished the slug until the. interior portion of the article.

I metal is extruded into theshank cavity, and Figures 1'} 3', 5., and 6 represent 80 a e the upbuilding of the wall. Still another inclusive, illustrating permitting the exterior rt-ion of the metal end views 0 object in its said several which forms the wall of the cup flow, sta I during the extruding process, OPPOSltQlY to lgures 2", t3 4", 5", 5, and 6" are secthe movement of the unch, thereby buildtional views illustrating instrumentalities ing up a depth of wa to the cup materially employed in developing the several stages 86 7 beyond the distance of' enetration of the illustrated by figures bearing the numbers punch into the original s ug. Another fea- 2 'to 6 and 2 to 6", inclusive. ture-consists in changing t e transverse di- Figure 7 is a view sug esting the applimension of the die cavity from the cupcation of steps correspon ing substantiall 7 35 forming portion to the shank-forming porto Figures 5 and 5,whereby the shank is go tion gradually, asby tapering or stepping, so flattened in central longitudinal relation to that the metal flowing into the wall of the the cup. cup under the displacing action of the punch Figures 8 to 12, inclusive, are views cormay take. a. diagonal direction and favor responding, respectivelg, to Figures 1 to 5. I t e development from 9 I feature consists in forming the cup in stages the original slug to the substantially comof progressively mcreasin dept and depleted device, in the production bf which creasing diameter, as by eveloping an Inthe two initial stepsare somewhat modified "tegrai shank and on by the combined exand Fi es 8" to 12, inclusive, are en I trudmg and wall owing operation, and views 0 parts shown in-Figures 8 to 12.

then forcin the piece thus formed through Fi ms 9', 10", and 11" are vertical seca reducing 'e which contracts the-cup upon tiona iews illustrating instrumentalities a smaller punch and flows the surplus metal em loy d for; developing the. work pieces still further in the direction of t 0 axis of shown in Figures 9, 9-, to 11, 11, inclusive.

'so the piece to increase the depth of the cup. on example ofau object having int al 1 5 still another feature consists in' forming a h nk and on for the production ofw 'ch fl m k'fr0m a tapered shank of the process'o the present invention'isespa round section by'pressmg the shank between' cially ada ted, is illustrated in Figures 6 a members which impingeathicker rtion of and 6, wherein, 1 re resents the cup, 2

the shank uhaeent t a cup in vance of and'3 a! oration in-the shank 'un of an electric cable terminal, the general construction and use cit which are well known, and inithe production of which the cup is usually of cylindrical form, while the shank is in the form of a flattened fin extending parallel to the axis of, and from one end of the cup, but in a plane offset from the axis and approximately tangential to the wall of the en This position of the shank is the result the particular manner of pressing an axially related tapered shank of cylindrical section, as hereinafter described with reference to Figures 4, 4*, 5

and 5, and the shank may take the form suggested by dotted lines at 2, in Figure 7, where it is centrally related to the cup 1.

a In roducing an article having the general c aracteristics of the integral cup and shankterminal shown in Figures 6, and 6, or suggested in Figure 7 a slug X of solid metal (Figures 1, 1) is procured from any suitable source, as by cuttin ofi a section of a more or less round ro of copper or other metal, and which will answer the purposes of the present invention even though it be of'com aratively irregular form and this slug is ro ped mto a blanking die A (Figure 2") an there subjected to the action of a plunger or punch B to convert the $1 into the blank (Figures 2 and 2'), which blank has a body portion indicated by the vertical dimension n and a reduced lower end y and a slightly cu ped or recessed upper end 3 with justified ed es 3 This b ank is then dropped into a ie 0 having a cup-forming cavity 0', and a shank-forming cavity C and in this die the blank 3 is subjected to the action of a punch D which is of less transverse dimension than l around the punch, the interior 'the cup cavity 0, but greater than the in ternal dimension of the cup ultimately to be formed, so that while the outer portion of the metal, by which the blank exceeds the diameter of the punch D, is left free and unrestrained from flowing upwardly ortion of the blank is displaced downward y into the shank-formingportion (J of the die C; in other words, the blank is converted into a artiallyfinished cup-portion 1' represented .ythe dimension a (Figure 3) and a par! tially finished integral shank-portion 2. The shank portion has now been developed by extrusion of the metal under the actlon of the punch, while the dimension n of the cup has been developed partly by the penetration of the punch into the blank 3 and partly by upward flow of the metal into the space between the punch and the die. .The blank 1*, 2 resulting from this stage, which is shown in Figures 3 and 3", is now dropped into the upper elongated portions E o the cup-drawing die E, having a on -finishing cavity E corresponding to the u timate external dimension of the cup to be formed;

and in this die, the blank 1*,2, is subjected to the action of a plunger F which forces said blank downwardly from the enlarged cavity E and through the smaller cup-finishing cavity E thereby drawin the sides of the cup blank 6 inwardly and upwardly and still further elongating said sides and forming the ultimate cup 1 having vertical dimenslon n An important feature in the construction of the dies for flowing a rtion of the metal upwardly into the wa l of the cup resides in the diagonal or flaring form given to the dies at the points C, E, which favors escape of the metal into the wall-forming space of the die. The blank 1, 2", obtained at this stage, which is shown in Figures 4 and 4*, is now ready to have its shank portion 2 flattened to the ultimate form 2 (Figures 5, 6, and 6) or the form suggested at 2' Figure 5), and this may readily be done y the following instrumentality.

If the flattened shank 2 is to lie in an oflset plane, as shown in Figures 6 and 6, the round symmetrically disposed shank 2 is first pressed between the flattening die H and the bed die G, as shown in Figure 5*, to develop a partially flattened but flaring shank 2 as suggested by dotted lines in Figure 5", and then pressed between finishing die H and bed die I, as shown in Figure 5. If the symmetrically disposed flat shank 2 is to be produced, the dles are chan ed accordingly. For instance, two mova le- .the movable die H (Figure 5") or the dies K, L, (Figure 7) develop their initial bite upon the shank 2 at the point or points 4, which is an a preciable distance inside of the taper or reduction in theshank; and the impressing face or faces are inclined away from the work-piece so that, as the metal is displaced by the bite of the dies, it is simultaneousl flowed in the direction of the axis of the s ank and away from the cup, thus materially elongating the shank by the time it reaches its flattened state. Moreover, the displacement of this larger diameter of the blank, where the initial bite occurs, develops substantial shoulders 5 (Figures 5 and 6) between the cup 1 and the flattened shank,- thereby permittin the development of width in the sham which is required by specification for the commercial article, and making a stronger connection between the i. shank and the cup, which connection flares I metal to produce a blank, comprising a cupures 9, 9, 9" and 10, 10, and 10", the dimension of the original slug or work-plece X (Figures 8, 8) is relied upon to provide the shank portion 2" of the blank without extrusion' or additional shaping; and the upper end of the slug is upset between a punch and a die, as suggested in Figure 9 in order to provide the blank 3 in addition to 1ts shank portion 2", with a head if of proper dimension and with suitably tapered side walls to permit the formation of a cup blank by intrusion of a punch and upward flowing of the displaced metal to increase the depth of the cup wall. This latter procedure is then accomplished by means ofthe die G and punch D, shown in Fi um 10*, and in which the cavity of the die flares upwardl and facilitates displacement of metal un er cupping action re ferred to, while the working end of the punch D is approximately conical so that the resulting work-piece takes the form shown in Figures 10 and 10". poiiit on the process can follow the details substantially as described in connection with Figures 4; to 6 or 7, inclusive, in that the cupped blank of Figure 10 is next forced 'througha reducing or drawing die E (Flgure 11) by means of a punch F in order to change to the cup shown at 1 in Figures 11 and 11", after which the shank-forming portion 2" can be flattened to produce the attaching shank 2, joined to the cup portlon 1' by means ofthe shoulder 5, and the finished shank can be punched by some such method as suggested in Figure 6*.

I claim:

1. The improvement inthe art of producing an object with an integral cup and shank, which consists in forging a piece of portion, a tapering portion an a shank portion, and then flattening the shank portion between dies which. impinge the tapered portion, as well as the shank portion in advance l of the remainder of the shank.

2. The improvement in the art of producing an object with an integral cup and shank, which consists in forging a piece of metal to produce a blank, comprising a cupportion, a tapering portion and a shank portion, and then flattening the shank portion between dies which impinge the tapered portion as well as the shank portion, the dies being-set toqimpinge against the tapered portion in advance of the remainder. of the shank. A

3. The improvement in the art of roducing an object with an integral cupan shank, which consists inforgin a piece of metal to produce a cup and a re uced shank joined together by a. tapered portion, and then From thisv flattening the shank between dies which impinge a ainst the tapered portion as well as the s ank portion, and with the working face of a die inclined to the per endicular of the line of die movement, there y causing the metal of the shank to flow away from the cup. I

4. The improvement in the art of roducing an object with an integral cup an shank, which consists in forgin a piece of metal to produce a blank comprising a cup portion,

a tapering portion, and a shank portion, and then flattening the shank between dies whichimpinge against the ta ered port-ion as well as the shank portion, .w ile the workin face of a die is inclined to the perpendicu arof the line of die movement, thereby causing the metal of the shank to flow awa from the cup, and thereafter completing t e flattening operation by pressure between surfaces perpendicular to the line of die movement. 4

5. The improvement in the art, of producing an object having an integral cup and shank, the same consisting in subjecting a metal blank to the action of a plunger in a cooperating die surrounding the plunger, and leaving a cup-wall space between them and formed with a shank cavity of lesser diameter than the plunger, a cup cavity which communicates with said shank cavity, an offset between said cavities corresponding substantially to the diameter of the plunger, and a second offset corresponding to vsaid wall space and by said die and'plunger; ex-

truding a reduced shear area of the blank I which communicates with said shank cavitg,

an ofli'set between said cavities correspon ing substantially to the diameter of the plunger, a second offset corresponding to said wall space and by said die and plunger; extruding a reduced shear area of the blank into the shank cavity and leaving in said cup cavity a wall defined by ashear area corresponding to the second offset; and

drawing the resultant form through a die to reduce the diameter of the cup wall and eliminate the second offset.

Signed at Chicago, Illinois, this 22nd day of April, 1924.

' CHARLES J. RATEIKE. 

